System and method for stabilizing vertically stacked sheet material

ABSTRACT

A system and method for stabilizing vertically stacked sheet material is disclosed. The sheet material may be construction wallboard. The system includes a bracket and an elongate flexible link element. The method includes attaching the bracket to the sheet material, attaching the flexible link element to a support structure such as vertical stud framing member, and attaching the flexible link element to the bracket to stabilize the vertically stacked sheet material.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 11/953,546, filed Dec. 10, 2007, entitled “SYSTEM AND METHOD FORSTABILIZING VERTICALLY STACKED SHEET MATERIAL”, now allowed, thecontents of which are incorporated herein by reference in the entirety.

FIELD OF THE INVENTION

The present invention is generally directed to the stabilization ofstored material, and more particularly to a system and method forstabilizing vertically stacked sheets of construction material.

BACKGROUND OF THE INVENTION

One of the most common methods today of constructing walls and barriersincludes the use of inorganic wallboard panels or sheets, such as gypsumwallboard, often referred to as wallboard or drywall. The term wallboardas used herein is intended to include construction material of a generalflat sheet shape, including but not limited to gypsum wallboard.

North America is one of the largest gypsum walllboard users in the worldwith a total wallboard plant capacity of 40 billion square feet peryear. Moreover, the home building and remodeling markets in NorthAmerica have increased demand the last five years, with an average newAmerican home containing more than 7 metric tons of gypsum.Additionally, the world market for gypsum as a construction materialcontinues to grow.

Walls and ceilings made with gypsum wallboard panels are conventionallyconstructed by securing the wallboard with screws, nails, or othersimilar fasteners to structural members, for example, vertically andhorizontally oriented pieces of wood or metal, commonly referred to asstuds. Wallboard is typically supplied in standard-sized sheets orpanels, and is frequently delivered to a construction site as stacks orbundles of wallboard.

The bundles of wallboard may contain approximately 26 to 30 individualsheets of wallboard. The wallboard is most frequently configured as 4ft. by 12 ft. sheets, with each sheet weighing approximately 90 lbs.Wallboard is also provided in 4 ft. by 8 ft. and 4 ft by 16 ft. sheets.Thus, bundles of wallboard may weight between approximately 2340 lbs and2700 lbs. The bundles of wallboard are delivered and stored at theconstruction site until needed.

At the construction site, the wallboard may be stored by horizontallystacking the wallboard on a horizontal surface, such as a flooringsurface, or the wallboard may be vertically stacked, such as against anunfinished wall. The wallboard is often vertically stacked when thewallboard is being stored on a second floor or higher level at aconstruction site where horizontal storage space is not readilyavailable. The wallboard may also vertically stacked on ground or lowerfloors if horizontal storage space is not available. The wallboard isoften vertically stacked by leaning the wallboard against a stud wallproximate to the location where the wallboard will be installed. It iscommon practice in the construction industry to vertically stackwallboard with a very small lean angle to prevent damage to thewallboard. Often, the lean angle, the angle from vertical that thewallboard is leaned towards the supporting surface, may be up toapproximately 20 degrees from vertical, and may be less than 5 degreesfrom vertical. The term vertically stacked is intended to encompass leanangles up to approximately 20 degrees from vertical for the remainder ofthis discussion. The small lean angle creates an unstable stack ofwallboard that may be tipped over by a small unintentional force.

The vertically stacked wallboard presents a safety problem atconstruction sites since the wallboard may be subjected to unintendedexternal forces, such as wind or accidental work site contact, which maycause the wallboard to unintentionally fall away from it's verticallystacked orientation. Because of the wallboard's considerable weight andsize, serious personal injury may result from such unintentionalmovement of the wallboard, either by contacting a person or forcing aperson into an unsafe position.

Because the wallboard is used as a wall surface, it is not practical totemporarily fix the wallboard directly to a vertical surface, such as astud, by nailing or other destructive methods. Furthermore, providingsupports and/or structures to temporarily stabilize the wallboard is notpractical due to the fast pace at which the wallboard is used.

What is needed is a system and method to stabilize substantiallyvertically oriented wallboard that is inexpensive and simple to install.

SUMMARY OF THE INVENTION

A first aspect of the disclosure includes a stabilization system forstabilizing a vertically oriented sheet of material including a bracketcomprising a front wall, a rear wall, and a top wall disposed betweenthe front wall and the rear wall, the front wall comprising a complianttab having a first hole therethrough, and a second hole configured to bealigned with the first hole when the compliant tab is folded across thefront wall, and an elongated flexible link element.

The front wall of the bracket may include protrusions generally directedtowards the bracket rear wall. The rear wall may also includeprotrusions generally directed towards the front wall. The top wall mayinclude a compliant top tab having a hole.

The elongated flexible link element includes a wire having a wirefastener disposed at one end thereof. The elongated flexible linkelements may be a metal wire and the wire fastener comprises an eyelet.In an alternative embodiment, the elongated flexible link element may bea nylon fastener.

The bracket may be metal and may be formed by stamping and forming ametal blank. Alternatively, the bracket may be a plastic or polymermaterial formed by molding.

A second aspect of the disclosure includes a method for stabilizing avertically stacked sheet of material including providing a verticallystacked sheet of a material supported against a support surface,mounting a bracket over a top edge of a sheet of the vertically stackedsheet of material, securing an elongated flexible link element to acomponent of the support surface, and attaching the elongated flexiblelink element to the bracket to stabilize vertically stacked sheet ofmaterial against the support surface. The vertically stacked sheet of amaterial may be vertically stacked wallboard.

The elongated flexible link element may be routed through a hole in atab formed in the mounting bracket before the elongated flexible linkelement is attached to the bracket.

The elongated flexible link element may be a metal wire and a fastenerdisposed at one end of the metal wire, and the elongated flexible linkelement is secured to the support surface by a fastener such as a screw,nail or staple. In an alternative embodiment, the elongated flexiblelink element is a nylon fastener such as a nylon wire tie.

The bracket used in the second aspect of the disclosure includes a frontwall, a rear wall, and a top wall disposed between the front wall andthe rear wall, the front wall comprising a compliant tab having a firsthole therethrough, and a second hole configured to be aligned with thefirst hole when the compliant tab is folded across the front wall, andprotrusions generally directed towards the rear wall.

The front wall of the bracket may further include protrusion generallydirected towards the rear wall. The rear wall may include protrusionsgenerally directed towards the front wall.

The method for stabilizing a vertically stacked sheet of material mayinclude two or more brackets to stabilize the vertically stacked sheetof material.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates of a construction site scenario where the system andmethod of the invention may be applied.

FIG. 2 illustrates an exemplary embodiment of a stabilization systemaccording to the invention.

FIG. 3 illustrates the stabilization system of FIG. 2 having theelongated flexible link element attached to the bracket.

FIG. 4 illustrates an exemplary application of the invention.

FIG. 5 illustrates an alternative exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows an illustration of a construction site scenario 10 that maybe prevented by the system and method according to the presentinvention. As can be seen in FIG. 1, a bundle of wallboard 15, which hasbeen vertically stacked against studs 20, has become destabilized and isfalling in the direction of the arrow 25. The falling bundle ofwallboard 15 is shown as either striking the worker 30 or forcing theworker 30 into an unsafe position.

FIG. 2 illustrates an exemplary embodiment of a stabilization system 200for stabilizing a substantially vertically stacked bundle of sheetmaterial (not shown) against a wall stud 210 or other similar wallstructure. The stabilization system 200 includes a bracket 215 and aflexible link element 220. The bracket 215 includes a front wall 225, arear wall 230, and a top wall 235 disposed between the top wall 225 andthe rear wall 230. The bracket 215 may be metal, such as steel, aluminumor other similar metal, and may be formed by stamping and forming thebracket by conventional metal working methods including stamping,punching, and bending. Alternatively, the bracket may be formed of aplastic or polymer material and formed by conventional plastic moldingtechniques.

The front wall 225 includes a front hole 239 and a front tab 240. Thefront tab 240 includes hole 241. The front tab 240 is formed from thefront wall 225 by any conventional forming methods including stamping,punching, cutting and other similar methods. In an alternativeembodiment, the front tab 240 may be adhered to the front wall 225 bywelding or other suitable technique for metal joining. The front tab 240is compliant and configured to allow the tab 240 to be folded across thefront wall 225 so as to align the hole 241 with the front hole 239.

The front wall 225 also includes optional protrusions 245, which havebeen formed into the front wall 225 by any conventional methodincluding, but not limited to stamping, punching and other similarforming methods. The protrusions are generally directed towards the rearwall 230 as shown in FIG. 2. The protrusions 245 have a generallytriangular shape, but other shapes including rectangular, square,circular and other similar shapes may be used. The protrusions 245 areconfigured to engage sheet material (not shown) when present between thefront and rear walls 225, 230. In an alternative embodiment, protrusions245 may be attached to the front wall 225 by welding or other suitabletechniques.

In alternative embodiments of the invention, protrusions 245 may beformed in the rear wall 230 and generally directed towards the frontwall 225, the protrusions may be formed in the rear wall 230 in additionto being formed in the front wall 225, or the protrusions may be omittedfrom both the front wall 225 and the rear wall 230.

The top wall 235 includes an optional top tab 236. The optional top tab236 includes a hole 237. The optional top tab 236 is disposed proximateto the front wall 225 as shown in FIG. 2. The optional top tab 236 isformed in the top wall 235 by stamping, punching, cutting, or othersimilar forming method, followed by working to orient the optional fronttab 236 substantially perpendicular to the plane of the top wall 235. Inalternative embodiments of the invention, the optional top tab 236 maybe positioned proximate the rear wall 230, between the front wall 225and the rear wall 230, or may be deleted.

As shown in FIG. 2, the front wall 225 has a length L₁ and a width W.The length L₁ may be between about 1 inch to about 5 inches, and morepreferably between about 1.5 inches and about 3 inches, and mostpreferably about 2 inches. As further shown in FIG. 2, the rear wall 230has a length L₂ and a width W, the width W being the same for the frontwall 225 and the rear wall 230. The length L₂ may be between about 1inch and about 7 inches, and preferably between about 2 inches and 5inches, and most preferably about 3 inches. The width W is selected toprovide the bracket 210 with sufficient strength and stability tosupport any sheet material stabilized by the bracket 215. The top wall235 has a depth D as shown in FIG. 2. The depth D is selected so thebracket 215 can be attached to of a single sheet of wallboard (notshown). For example, if the wallboard has thickness of approximately 0.5inches, the depth D may be selected to be between greater than about 0.5inches and about 1 inch, preferably about 0.75 inches. Alternatively,the depth D may be selected so the bracket 210 may be attached to morethan one sheet of wallboard (not shown). The dimensions of the bracket215 may vary considerably, and are dependent upon the thickness of thesheet material and strength of the material chosen to form the bracket215. The dimensions may be determined by one of ordinary skill in theart based on the sheet material dimensions, bracket material andapplication so as to minimize the bracket dimensions, which reduce cost,and yet provide the desired degree of stability for the wallboard.

As additionally shown in FIG. 2, the flexible link element 220 attachesthe bracket 215 to wall stud 210. The link element 220 includes a wire255 or cable and a wire fastener 260 disposed at one end of the wire255. The wire 255 may be a metal or plastic, but preferably is metal.For example, the wire 255 may be a stranded steel wire having a diameterof between about 3/64 inch to about ¼ inch, and preferably be a ⅙ inchdiameter 7 strand steel wire, commonly referred to as 7×7 wire having abreak strength of about 480 lbs. The wire fastener 260 may be formed ofmetal, ceramic, or plastic material. The wire fastener 260 includes ahole or eyelet 261 for receiving a fastener such as a fine threaddrywall screw, screw, nail, staple or other similar fastener (not shown)for attaching the wire fastener 260 to the stud 210. The wire fastener260 may be attached to the wire 255 by any conventional methodsincluding crimping, soldering, gluing or other similar methods. In oneembodiment, the wire fastener 260 is metal side eyelet fastener that hasbeen crimped onto an end of the wire 255.

In an alternative embodiment of the invention, the flexible link elementmay be a nylon or other similar plastic or polymer fastener having awire section and a wire securing element disposed at one end of the wiresection. For example, a nylon fastener having a wire section withratchet serrations on one side and a ratcheting terminal end section maybe used. The ratcheting terminal end section may have an apertureprovided with a pivoted pawl having teeth that engage the ratchetserrations of the wire when the free end of the strap is passed throughthe aperture. The nylon fastener may be a wire tie or zip tie as iscommonly referred to in the art.

The wall stud 210 includes a front surface 262 and a side surface 265.The wall stud 210 may be formed of wood, metal or other similarconstruction material.

Referring to FIG. 3, the link element 220 is attached to the sidesurface 265 of the wall stud 210 by a fine thread drywall screw 267 orother similar fastener including, but not limited to, nails. The linkelement 220 is preferably attached to the side surface 265 instead ofthe front surface 262 to increase retention strength of thestabilization system 200, as would be appreciated by one of ordinaryskill in the art. However, in alternate embodiments, the link element220 may be attached to the front surface 262.

After the link element 220 is attached to the stud 210, the wire 255 isrouted through the hole 237 in the optional top tab 236 and disposedacross the front wall 225 of the bracket 215 as shown in FIG. 3. Thelink element 220 is securely attached to the bracket 215 by folding thetab 240 across the wire 255, aligning the hole 241 (FIG. 2) with thefront hole 239 (FIG. 2), and securing the tab 240 to the front wall 225by a machine screw 270 or other similar fastener as shown in FIG. 3.Preferably the machine screw 270 has a short length sufficient tosecurely engage the tab 240 to the front wall 225 while minimizingcontact with sheet material (not shown) adjacent the front wall 225.

FIG. 4 illustrates an exemplary embodiment of using stabilization system200 to stabilize a bundle 410 of individual sheets of wallboard 412 thathas been vertically disposed against front surfaces 415 of studs 420.The bundle 410 may include 26 to 30 individual sheets of wallboard 412having a thickness of between about ¼ inch and about 1 inch, althoughfewer sheets are depicted for illustration purposes. The wallboard isconfigured as a 4 ft. by 12 ft. sheet, however it should be appreciatedby one of ordinary skill in the art that the wallboard may be configuredas a 4 ft. by 8 ft. sheet, a 4 ft by 16 ft. sheet, or other sized sheetas known in the art. It should also be appreciated by one of ordinaryskill that fewer or greater than 26 to 30 individual sheets may bestabilized by the stabilization system 200.

As can be seen in FIG. 4, the flexible link element 220 has beenattached to a side surface 425 of a stud 420, and the bracket 210 hasbeen mounted over a top edge 430 of an outer sheet 435 of the bundle410. The flexible link element 220 has been attached to the side surface425 by a fastener (not shown) such as a screw, wood screw, nail, stapleor other similar fastener. The tab (not shown) has been folded over thewire 255 and secured to the front wall 225, which secures the wire 255to the front wall 225. As can be appreciated from FIG. 4, very little ofthe force from the weight of the bundle 410 is applied to thestabilization system 200 because of the substantially verticalorientation of the bundle of wallboard 410 as shown. In this exemplaryembodiment, two stabilization systems 200 have been used to provideincreased safety and redundancy. Alternatively, one or more than twostabilization systems 200 may be used to provide the degree of safetydesired.

Several exemplary methods may be used to remove individual sheets 430from the bundle 410. In one exemplary embodiment, the link elements 220may be cut between the bracket 210 and the wire fasteners 260 to provideaccess to individual sheets of wallboard 412. In a second exemplaryembodiment, the screws (not shown) attaching the wire fastener 260 tothe studs 420 may be removed from the studs 410 providing access toindividual sheets of wallboard 412. In a third exemplary embodiment, thefastener securing the front tab to the front wall 225 may be loosened orremoved, allowing the wire 255 of the link element to be unsecured fromthe bracket 210 to provide access to the wallboard 412.

It should be appreciated by one of ordinary skill in the art, that inany of the exemplary methods presented above, the wire of the flexiblelink element may be re-attached to brackets 210 present on the frontsheet, or new brackets 210 may be disposed on a new front sheet andexisting or new wire may be used to re-attached the bracket to the studs420.

In an alternative embodiment of the invention shown in FIG. 5, a nylonfastener 520 having a wire portion 525 and a ratcheting end section 530disposed at one end of the wire portion 525 is as the flexible linkelement. The wire portion 525 is wrapped around a stud 210 and securedthereto by passing a free end of the wire portion 525 though theratcheting end section 530 and tightened as shown in FIG. 5. The wireportion 525 is brought across the front wall 225 of bracket 215, similarto the embodiments discussed above, and secured to the bracket 215 in asimilar manner as discussed above.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. A stabilization system for stabilizing a vertically oriented sheet ofmaterial, comprising a bracket comprising a front wall, a rear wall, anda top wall disposed between the front wall and the rear wall, the front,rear and top walls defining a gap configured to receive an edge of thesheet of material; and an elongated flexible link element attached tothe bracket and configured to be attached to a vertical wall support. 2.The system of claim 1, wherein the elongated flexible link elementcomprises a wire having a wire fastener disposed at one end thereof. 3.The system of claim 1, wherein the front wall further comprisesprotrusions generally directed towards the rear wall.
 4. The system ofclaim 1, wherein the rear wall comprises protrusions generally directedtowards the front wall.
 5. The system of claim 1, wherein the top wallcomprises a compliant top tab having a hole.
 6. The system of claim 5,wherein the wire fastener comprises an eyelet.
 7. The system of claim 1,wherein the elongated flexible link element is a nylon fastener.
 8. Thesystem of claim 1, wherein the bracket is formed of a plastic or apolymer material.
 9. The system of claim 1, wherein the bracket isformed of a metal.
 10. The system of claim 1, wherein the bracket isformed by stamping and forming a metal blank.
 11. The system of claim 1,wherein the bracket is formed by molding a polymer or plastic.